bens suodatin

8/22/2019 Bens Suodatin

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Replace fuel filter

General instructions

Petrol fuel

the fuel level drops, the in-tank pump draws in air and the engine stalls. As a consequence of a safety circuit, the pumpwitches off as soon as the engine stalls and the control unit therefore receives no rpm signal. This safety circuit is included in allnjection systems for petrol engines. Repeated attempts to start the engine (3 to 4 times) do not damage the fuel pump either.

Note: Shortage of fuel is not a possible cause of pump failures.

Diesel Fuel

n the

Y 17 DT it is permissible to activate the starter for up to 40 sec. until the engine starts. Y 25 DT the engine must be switched on. Wait 10 sec. and if it is then possible to start, the preliminary fuel pump is

activated.

Note: The pump system of diesel engines is not damaged by shortage of fuel and repeated attempts at starting the engine,xception:

DI-engines (Y 20 DTL, Y 20 DTH, Y 22 DTH, Y 22 DTR)

The tank of DI-engines may not be run dry.

The DI-fuel system is bled using the bleeder unit KM-948.

Note: Having fresh fuel does not necessarily mean that it is also clean - this depends on where it was stored. Any grain of sandn the "clean" filter end can destroy the injection pump.

Please follow the relevant instructions in group "L".

Petrol engine

Warning: Escaping fuel - observe safety instructions and national regulations! Dispose of collected fuel - observe disposal andafety regulations.

Note: The special tool used in the following operation is particularly suitable for meeting the safety instructions and nationalegulations. It is available from the following address under the designation of "Device for changing the fuel filter" with articleumber 600250:

F. BOGE GmbH

Postfach 1229

D-36396 Steinau a. d. Str.

Germany

Fuel filter change, petrol engines

Remove, detach

Unclip handbrake cable (3) from bracket (4)Unclip return line (2) from bracket (1)


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Attach head of special tool (2) to fuel filter (1) Threaded connection piece (3) points downward Push rubber seal (arrow) onto fuel filter housing

(entire surface)Adjust turnbuckle accordinglyClamp using clamping bracket


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Warning: The fuel filter is under pressure. Check that special tools firmly attached. Adhere to specified sequence. Do not removeuel lines until fuel has stopped escaping from the fuel filter.Observe safety instructions and national regulations pertaining toescaping fuel.

Attach fuel collection vessel (3) to head of special tool (1) Screw fuel collection vessel to threaded connection

piece and tighten.Vent fuel filter

perforate as far up as possible (arrow) using the

pliers (5) provided with the special toolremove and seal 2 fuel lines (2, 4) from fuel filter reduce at quick acting closure using KM-796 seal using KM-807

When fuel filter has been emptied, remove special tool Remove collection vessel Remove head of special tool

Release clamping bracket

Note: The integrated drill makes a hole in the fuel filter housing.The escaping fuel flows into the collection vessel.

Release and remove fuel filter (1) Push fuel filter forward out of bracket (2)

Lift retaining tab (arrow)


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nstall, attach

mportant: Note repair instructions for fuel lines and fast-action closings - see "Repair Instructions".Use new clips.

Petrol engine (fuel grade EN 2281)

, external)

Note: "External" means that no in-tank fuel filters are replaced, as in the Agila. The main service does not include replacing in-ank fuel filters.

Remove, detach

Insert new fuel filter push into the bracket (3) from the front

Observe flow directionconnect 2 x fuel line (1) and (2) to fuel filter

Remove 2 KM-807 Attach 2 fuel lines to fuel filter using quick acting

closure

Clip handbrake cable (3) into bracket (4)Clip return line (2) into bracket (1)

nsert new fuel filter

Check / visually check

Check 2 fuel line fast acting closures to fuel filter for leaks with engine running

Reduce injection pressure at "service port" (or Schrader valve)

using MKM-925, then release fast acting closures (1) at fuel filterusing KM-792(2). Seal fuel lines using KM-807. Open retainer andemove fuel filter.


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Note: The injection pressure at the "service port" must be relieved as otherwise, at a system pressure of 380 kPa, the fuel canquirt a long way into the air or into eyes (despite protective goggles), because the change is undertaken on the lifting platform,e. at eye level.

Fuel filter change, diesel engines

Remove, detach

nstall, attach

Slide connection clips (1) onto new fuel filter. Insert fuel filter inbracket note through-flow direction. Remove sealing plug. Slideuel lines onto fuel filter connections until quick fittings engagenoticeably.

Remove fuel filter housing.

Detach fuel supply line (1) and fuel return line (2) from fuel filterhousing cover using KM-796.

Remove fuel preheating wiring harness plug (3).

Pull fuel filter housing (4) out of holder from above. Ensure that nouel escapes.


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Warning: Escaping fuel, observe safety instructions and nationalegulations.

Remove, detach

Remove fuel filter housing.

Remove fuel filter housing cover (1) from fuel filter housing (3).Remove fuel filter element (2) from fuel filter housing and place insuitable container.

Drain rest of fuel from fuel filter housing into suitable container.

Cleaning

Clean fuel filter housing cover and fuel filter housing with lint-freecloth.


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nstalling and attaching diesel engines

Slide fuel filter housing into holder from above.

Attach wiring harness plug to fuel preheater.

Attach fuel supply line and fuel return line to fuel filter housing cover.

Note: Tighten central bolt. Tightening torque 6 Nm.

Bleed fuel system, diesel engines.

ee operation "Bleed fuel system (diesel engines)" in service guide, component group "L".

Replace fuel filter, X 25 DT (Omega-B)

Assemble

nsert fuel filter element and fill fuel filter housing with new dieseluel (to just below the edge).

Assemble components as shown - use new gaskets.

For X 20 DTL, Y 20 DTL, Y 20 DTH, Y 22 DTR: Bleed fuel systemsee operation "Bleed fuel system, diesel engines".

1. Central bolt - tightening torque 6 Nm.

2. Central bolt seal

3. Fuel filter housing cover

4. Fuel filter housing cover seal

5. Fuel filter element

6. Spring

7. Fuel filter housing

Note: Escaping fuel, observe safety instructions and nationalegulations!

Remove, detach


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nstall, attach, X 25 DT (Omega-B)

Coat sealing ring with silicon grease (white) and attach to "single stage box filter" (fuel filter housing) - (pay attention to correcttting of fuel preheater!).

Attach fuel lines to "single stage box filter" (fuel filter housing) with new sealing rings (tightening torque 15 Nm).

Attach wiring harness plug to fuel preheater.

Attach wiring harness plug to temperature switch.

Vent fuel system.

Bleed fuel system, X 25 DT (Omega-B)

Detach wiring harness plug (3) from temperature switch.

Detach wiring harness plug (2) from fuel preheater.

When replacing fuel filter: rebuild all detachable parts.

Detach fuel lines (1) from "single stage box filter" (fuel filterhousing).

Remove fuel filter.

Remove, detach

Remove engine cover.

Undo closure bolt (1) at fuel filter by approx. two turns.

Operate starter until bubble-free fuel escapes from the closurebolt. Close closure bolt. Collect escaping fuel.

Checking / Visual inspection, X 25 DT (Omega-B)

Whilst operating the starter, slacken all the injection lines at thenjection nozzle holder in sequence using a line wrench KM-8122) until fuel escapes from the injection lines.


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Seal injection lines again (tightening torque 25 Nm).

Collect escaping fuel.

Fit engine cover.

Fuel filter Z 13 DT

A newly developed diesel fuel filter comes into use with the Z 13 DT engine.

The fuel heating, fuel temperature sensor and water level sensor for the fuel filter housing are also housed in the fuel filterousing in the diesel.

The common-rail diesel injection technology needs a high level of water drainage from the fuel to ensure that it functions in the

est possible way.

The newly developed diesel fuel filter has a higher water separation rate than conventional diesel fuel filters. Its efficiency ispproximately 90%.

As a consequence of the higher water separation rate when the vehicle is in motion, more separated out water occurs in theiesel fuel filter housing. The water reservoir is larger than in conventional diesel fuel filter housings so that this increased


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uantity of water can be held.

Service:the water level in the diesel fuel filter housing rises to a significant level, the water level sensor for the fuel filter housing reactsnd an indicator is illuminated on the dashboard.

n this case, the water must be drained from the diesel fuel filter housing.

A new special tool is used to enable the fuel filter element to be changed within the scope of the specified replacement intervals.

To enable the fuel filter element to be replaced, it is necessary to unscrew the cover of the diesel fuel filter housing with the aid of

he special tool EN-46784.

The tool EN-46784 will be despatched within the scope of the longerm order when the Z 13 DT engine is introduced.

Diesel fuel filter housing, Z 13 DT


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Replace Diesel Fuel Filter Element, Z 13 DT

Note: Escaping fuel, observe safety instructions and national regulations.

Remove, detach, Z 13 DT

Remove diesel fuel filter housing.

1 Connection, fuel filter supply line 2 Connection, fuel filter return line

3 Connection, supply line, high pressure pump 4 Connection, fuel preheating

5 Drain plug 6 Connection, temperature sensor

Open diesel fuel filter housing with EN-46784, to do this clampdiesel fuel filter housing with EN-46784-020 (3) in vice. Opencover of fuel filter housing (2) with EN-46784-010 (1).


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Remove screw-on cover (1) of diesel fuel filter housing (5)

Remove filter element (3) with upper part of housing (2)

Remove seal ring (4)

Turn element (3) 50 anticlockwise.

EN-46784-20 (6) is clamped in the vice.


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Clean cover of fuel filter housing and the inside of the diesel fuel filter housing with a lint-free cloth.

Assemble

nsert fuel filter element and top up diesel fuel filter housing up to just below the edge with clean diesel fuel.

nstall diesel fuel filter housing.

Replace fuel filter, Y 25 DT (Omega-B)

Note: Escaping fuel, observe safety instructions and national regulations!

Removing, installing, Y 25 DT (Omega-B)

Assemble components as shown:

nsert new filter element (3)

Replace seal ring (4)

Turn element (3) 50 clockwise in the upper part of the housing2).

Note: Upper part of housing only fits in one position. Incorrectassembly is impossible.

Attach screw-on cover (1) to diesel fuel filter housing (5).

EN-46784-20 (6) clamped in the vice.

Screw in the screw-on cover (1) and tighten with EN-46784-10 -ightening torque 30 Nm.

Disconnect wiring harness plug (4) for fuel filter housing pressuresensor.

Detach fuel filter housing pressure sensor (5) from fuel filterhousing.

Detach fuel lines (1) and (2) from fuel filter housing (notenstallation position!).

Slacken fastening screw (3) and pull fuel filter out of "fuel filterholder".


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nstalling, attaching, Y 25 DT (Omega-B)

nsert fuel filter into "fuel filter holder" and tighten fastening screw.

Attach fuel lines to fuel filter housing note installation position.

nstall fuel filter housing pressure sensor.

Note: To bleed the fuel system: Switch ignition on and leave switched on for approx. 1 minute. During this period, the fuelystem is bled.

) For information on fuel quality see exhaust emissions test publication

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